EP2464516A1 - A multi-layer laminate structure and manufacturing method - Google Patents
A multi-layer laminate structure and manufacturing methodInfo
- Publication number
- EP2464516A1 EP2464516A1 EP10745095A EP10745095A EP2464516A1 EP 2464516 A1 EP2464516 A1 EP 2464516A1 EP 10745095 A EP10745095 A EP 10745095A EP 10745095 A EP10745095 A EP 10745095A EP 2464516 A1 EP2464516 A1 EP 2464516A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- layer
- frame
- surface portion
- width
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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- HVMJUDPAXRRVQO-UHFFFAOYSA-N copper indium Chemical compound [Cu].[In] HVMJUDPAXRRVQO-UHFFFAOYSA-N 0.000 description 3
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- UIPVMGDJUWUZEI-UHFFFAOYSA-N copper;selanylideneindium Chemical class [Cu].[In]=[Se] UIPVMGDJUWUZEI-UHFFFAOYSA-N 0.000 description 1
- LCUOIYYHNRBAFS-UHFFFAOYSA-N copper;sulfanylideneindium Chemical class [Cu].[In]=S LCUOIYYHNRBAFS-UHFFFAOYSA-N 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
- B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
- B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
- B32B17/10889—Making laminated safety glass or glazing; Apparatus therefor shaping the sheets, e.g. by using a mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/0044—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 for shaping edges or extremities
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B30—PRESSES
- B30B—PRESSES IN GENERAL
- B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
- B30B15/04—Frames; Guides
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
- B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
- B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2457/00—Electrical equipment
- B32B2457/12—Photovoltaic modules
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B32B37/1009—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure using vacuum and fluid pressure
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness
- Y10T428/24612—Composite web or sheet
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24777—Edge feature
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24851—Intermediate layer is discontinuous or differential
- Y10T428/24868—Translucent outer layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
- Y10T428/24926—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including ceramic, glass, porcelain or quartz layer
Definitions
- the present invention relates to a multi-layer laminate structure and method of manufacture, more particularly to a method of constructing the multi-iayer laminate structure utilizing a laminate frame and at least one energy activated flowable polymer.
- Efforts to improve the manufacturing of multi-layer laminate structures is an on-going endeavor. It is believed that one problem associated with the manufacture of multi-iayered laminate structures is the ability to manufacture a part with consistent dimensionai/geometric characteristics (e.g. length, width, thickness, profiles). Another problem may be manufacturing inefficiencies, such as high scrap rates, slow cycle times, and/or the need for secondary operations (e.g. secondary trimming or milling operations). One potential reason for such issues may be due to the dimensional/geometric tolerances of each individual layer that make up the multilayer laminate structures. Another potential reason for such issues may be due to the disparity in the material properties of the layers (e.g. thermal expansion/contraction) and the effect these properties have during the lamination process.
- the present invention is directed to a multi-layer laminate structure and method of manufacture, more particularly to a method of constructing the multi-layer laminate structure utilizing a laminate frame and at least one energy activated flowable polymer, and in one preferred embodiment to a multi-layer laminate structure that serves as an intermediate assembly of a photovoltaic device.
- the invention addressing one or more of the issues/problems discussed above.
- a method of constructing a multi-layer laminate structure including at least some of the steps of: a. providing a lamination frame, wherein the frame includes a first frame surface, a second frame surface and an external side frame surface interconnecting the first and second surfaces defining a frame thickness, further wherein the frame includes an internal side frame surface that projects towards the second frame surface from the first frame surface at least through a portion of the frame thickness defining a first frame pocket and a first frame pocket side wall profile; b.
- first layer including a first layer top surface portion, first layer bottom surface portion, and a first layer side surface portion interconnected between the top and bottom portions, wherein the first layer has a first layer length and first layer width adapted to fit within the first frame pocket; c. providing a second layer including a second layer top surface portion, second layer bottom surface portion, and a second layer side surface portion interconnected between the top and bottom portions, wherein the second layer includes an energy activated flowable polymer and further wherein the second layer has a second layer length, a second layer width, and a second layer thickness such that it can at least partially flow into and fill at least a portion of a first gap between the internal side frame surface and the first layer side surface portion; d. providing an energy source; e.
- the first layer to the first pocket introducing the first layer to the first pocket; f. placing the second layer bottom surface portion at least partially in communication with the first layer top surface portion creating a multi-layer stack; g. applying the energy source to the lamination frame, the multi-layer stack, or both, causing the energy activated flowable polymer to bond to the first iayer and at least partially flow into the first gap between the first layer side surface portion and the internal side frame surface creating a bead with a bead width and a bead depth, the bead depth defined by a depth of the internal side frame surface; h. allowing the energy activated flowable polymer to at least partially solidify, forming the multi-layer laminate structure; and i. separating the multi-iayer laminate structure from the lamination frame.
- the invention may be further characterized by one or any combination of the features described herein, such as: The method as set forth above further including one or more of the following steps: (1)providing a third layer including a third layer top surface portion, third layer bottom surface portion, and a third layer side surface portion interposed between the top and bottom portions; and placing the third layer in at least partial communication with the second layer top surface portion or with the second iayer bottom surface portion; wherein these steps occur before step g above; (2) the third iayer has a third layer length and third layer width less than that of the first pocket; causing the energy activated flowabie polymer to bond to the third iayer and at least partially flow into a third gap between the third layer side surface portion and the internal side frame surface creating the bead that is coextensive with that of step g above; (3) the third layer has a third layer length and third layer width greater than that of the first pocket; (4) the first frame pocket side wall profile tapers inward by at least a 1.5° angle over at
- a laminate frame including a first frame surface; a second frame surface; and an external side frame surface interconnecting the first and second surfaces defining a frame thickness; the frame includes an internal side frame surface that projects towards the second frame surface from the first frame surface at least through a portion of the frame thickness defining a first frame pocket and a first frame pocket side wall profile.
- the invention may be further characterized by one or any combination of the features described herein, such as a frame section that defines a second frame pocket and a second frame pocket side wall profile; the first frame pocket side wail profile tapers inwards by at least a 5° angle over at least a portion of the first frame pocket side wall as it projects towards the second frame surface; the laminate frame includes a keeper pocket; and inserted in the first pocket a first layer and a second layer of an energy activated flowable polymer and optionally a photovoltaic cell assembly interposed between the first and second layers.
- a multi-layer laminate structure including: at least two adjoining layers, the layers including: a first layer including a first top surface portion, a first bottom surface portion, and a first side surface portion interconnected between the first top and the first bottom portions, a second layer including a second top surface portion, a second bottom surface portion, and a second side surface portion interconnected between the second top and the second bottom portions, wherein the second layer comprises an energy activated fiowabie polymer; wherein the second layer at least partially is bonded to a portion of the side surface portion of the first layer creating a bead of the energy activated flowable polymer about at least a portion of the periphery of the first layer, further wherein the bead has an untrirnmed outer surface.
- the invention may be further characterized by one or any combination of the features described herein, such as the first layer comprises a glass plate; the structure includes a third layer and a fourth layer; the second, third, or fourth layer comprises a photovoltaic cell assembly; the second, third, or fourth layer comprises a back sheet; at least a portion of the back sheet includes a second energy activated flowabie polymer; the photovoltaic cell assembly comprises at least a cell portion and the cell portion is at ieast 5mm from an exterior edge of the multi-layer laminate structure; the structure includes five or more layers; and a structure including a plurality of laminate frames enabling multiple laminates to be made simultaneously.
- FIG. 1 is a partial side and or sectional view of one possible multi-layer laminate structure according to the teachings of the present invention.
- FIG. 2 is a partial side and or sectional view of another possible multilayer laminate structure according to the teachings of the present invention.
- FiG. 3 is an exploded view of another possible multi-layer laminate structure according to the teachings of the present invention.
- FiG, 4 is a plan view of an exemplary photovoltaic ceil assembly.
- FiG. 5 is a perspective view of one possible laminate frame according to the teachings of the present invention.
- FiG. 6 is a partial sectional view of the frame of FIG. 5.
- FiG. 7 is a partial sectional view of another possible laminate frame according to the teachings of the present invention.
- FiG. 8 is a partial sectional view of another possible laminate frame according to the teachings of the present invention.
- FIG. 9 is a perspective view of another possible laminate frame according to the teachings of the present invention.
- FiG. 10 is a perspective view of another possible laminate frame according to the teachings of the present invention.
- the present invention is directed to a multi-layer laminate structure and method of manufacture, more particularly to a method of constructing the muiti-layer laminate structure utilizing a laminate frame and at least one energy activated flowabie polymer.
- the multi-layer laminate structure is an intermediate assembly of a photovoltaic device. Examples of the various layer combinations can be seen in Figs. 1-3 and various configurations of the laminate frame can be seen in Figs. 5-10 (Fig. 4 showing a photovoltaic cell assembly).
- the multi-layer laminate structure 100 may include a plurality of individual layers (e.g. first layer, second layer, third layer, or more) which are at least partially bonded together to form the multi-layer laminate structure 100. It is also contemplated that in the assembled multi-layer laminate structure 100, that any given layer may at least partially interact/interface with more than just its adjacent layer (e.g. first layer may interact/interface at least partially with the third layer).
- first layer may interact/interface at least partially with the third layer.
- Each individual layer may be defined as having a height, length and width, and thus a volume. Each layer may also have a profile that is consistent along its height, length or width or may be variable therein. Each layer may have top, bottom, and interposed side surfaces. Each individual layer may be monolithic in nature or may itself be a multi-layer construction or an assembly of constituent components. In a preferred embodiment, at least some of the layers have a thickness that may range from as small as about 0.001mm to about 2.0mm or more.
- any layer of the multi-layer laminate structure 100 may contain any or none of the materials or assemblies. In other words, any particular layer embodiment may be part of any of the layers of the multi-layer laminate structure 100.
- one or more of the layers may function as an environmental shield ("shield layer”) for the multi-layer laminate structure 100 generally, and more particularly as an environmental shield for the successive layers.
- This layer is preferably constructed of a transparent or translucent material that allows light energy to pass through to at least one underlying layer.
- This material may be flexible (e.g. a thin polymeric film, a multi-layer film, glass, or glass composite) or be rigid (e.g. a thick glass or PlexiglasTM such as polycarbonate).
- the material may also be characterized by being resistant to moisture/particle penetration or build up.
- the first layer may also function to filter certain wavelengths of light such that preferred wavelengths may readily reach the opposite side of that layer, e.g.
- the first layer material will also range in thickness from about 0.05mm to 10.0mm, more preferably from about 0.1 mm to 4.0mm, and most preferably from 0.2mm to 0.8mm.
- Other physical characteristics at least in the case of a film, may include: a tensile strength of greater than 20MPa (as measured by JIS K7127: JSA JIS K 7127 Testing Method for Tensile Properties of Plastic Fiims and Sheets published in 1989); tensile elongation of 1 % or greater (as measured by JIS K7127); and water absorption (23 0 C 1 24hours) of 0,05% or less (as measured per ASTM D570 -98(2005)).
- one or more of the layers may serve as a bonding mechanism ("bonding layer"), helping hold some or all of any adjacent layers together, in some case (although not always), it should aiso allow the transmission of a desirous amount and type of light energy to reach adjacent layers.
- the bonding layer may also function to compensate for irregularities in geometry of the adjoining layers or translated though those layers (e.g. thickness changes).
- the bonding layer may consist essentially of an adhesive film or mesh, preferably an olefin (especially functi ⁇ nalized olefins such as silane grafted olefins), EVA (ethylene-vinyl-acetate), silicone, PVB (poly-vinyi-butyral) or similar material.
- the preferred thickness of this layer range from about 0.1 mm to 1.0 mm, more preferably from about 0.2 mm to 0.8 mm, and most preferably from about 0.25 mm to 0.5 mm.
- one or more of the layers may be constructed of any number of known photovoltaic cells or cell assemblies ("PV layer”) commercially available or may be selected from some future developed photovoltaic cells. These cells function to convert light energy into electrical energy.
- the photoactive portion of the photovoltaic DCi is the material which converts light energy to electrical energy. Any material known to provide that function may be used including crystalline silicon, amorphous silicon, CdTe, GaAs, dye-sensitized solar cells (so-called Gratezel cells), organic/polymer solar cells, or any other material that converts sunlight into electricity via. the photoelectric effect.
- the photoactive layer is preferably a layer of IB-IMA-chalcogenide, such as IB-INA-selenides, IB-illA- suifides, or iB-IUA-selenide sulfides. More specific examples include copper indium selenides, copper indium gallium selenides, copper gallium selenides, copper indium sulfides, copper indium gailium sulfides, copper gallium selenides, copper indium sulfide selenides, copper gallium sulfide selenides, and copper indium gailium sulfide seienides (all of which are referred to herein as CiGSS).
- IB-IMA-chalcogenide such as IB-INA-selenides, IB-illA- suifides, or iB-IUA-selenide sulfides. More specific examples include copper indium selenides, copper indium gallium selenides, copper gallium selenides, copper indium sul
- the photovoltaic cell assembly is a cell that can bend without substantia! cracking and/or without significant loss of functionality.
- Exemplary photovoltaic cells are taught and described in a number of patents and publications, including US3767471 , US4465575, US20050011550 A1.
- EP841706 A2 US20070256734 A1 , EP1032051 A2, JP2216874, JP2143468, and JP10189924A, incorporated hereto by reference for ail purposes.
- one or more of the layers may also serve as an environmental protection layer ("back sheet layer”), for example to keep out moisture and/or particulate matter from the layers above (or beiow if there are additional layers).
- back sheet layer e.g. a thin polymeric film, a meta! foil, a multi-iayer film, or a rubber sheet.
- the back sheet material may be moisture impermeable and also range in thickness from about 0.05mm to 10.0 mm, more preferably from about 0.1mm to 4.0mm, and most preferably from about 0.2mm to 0.8mm.
- Other physical characteristics may include: elongation at break of about 20% or greater (as measured by ASTIvI D882-09); tensile strength or about 25MPa or greater (as measured by ASTM D882-09); and tear strength of about 70kN/m or greater (as measured with the Graves Method).
- elongation at break of about 20% or greater (as measured by ASTIvI D882-09); tensile strength or about 25MPa or greater (as measured by ASTM D882-09); and tear strength of about 70kN/m or greater (as measured with the Graves Method).
- preferred materials include glass piate, PET, aluminum foil, Tedlar® (a trademark of DuPont) or a combination thereof.
- one or more of the layers may act as an additional barrier layer (“supplemental barrier layer”), protecting the adjoining layers above from environmental conditions and from physical damage that may be caused by any features of the structure on which the multi-layer laminate structure 100 is subjected to (e.g. for example, irregularities in a roof deck, protruding objects or the like), It is also contemplated that a supplemental barrier layer could provide other functions, such as thermal barriers, thermal conductors, adhesive function, etc. It is contemplated that this is an optional layer and may not be required.
- the supplemental barrier sheet may be a singie material or a combination of several materials, for example, it may include a scrim or reinforcing material.
- the supplemental barrier sheet material may be at least partially moisture impermeable and also range in thickness from about 0.25mm to 10.0mm, more preferably from about 0.5mm to 2.0mm, and most preferably from 0.8mm to 1.2mm. It is preferred that this layer exhibit elongation at break of about 20% or greater (as measured by ASTM D882-09); tensile strength or about 10MPa or greater (as measured by ASTM D882-09); and tear strength of about 35kN/m or greater (as measured with the Graves Method).
- the barrier layer could be comprised include thermoplastic polyolefin (“TPO”), thermoplastic elastomer, olefin block copolymers (“OBC”), natural rubbers, synthetic rubbers, polyvinyl chloride, and other elastomeric and plastomeric materials.
- TPO thermoplastic polyolefin
- OBC olefin block copolymers
- the protective layer could be comprised of more rigid materials so as to provide additional structural and environmental protection. Additional rigidity may also be desirable so as to improve the coefficient of thermal expansion of the multilayer laminate structure 100 and maintain the desired dimensions during temperature fluctuations.
- protective layer materials for structural properties include polymeric materials such poiyolefins, polyester amides, polysulfone, acetel, acrylic, polyvinyl chloride, nylon, polycarbonate, phenolic, polyetheretherketone, polyethylene terephthalate, epoxies, including glass and mineral filled composites or any combination thereof.
- the multi-laminate structure 100 consists essentially of two layers, a first layer 10 and a second layer 20.
- the first layer (“shield layer”) 10 may comprise a glass material (e.g. sheet glass) and the second layer 20 ("bonding layer") an energy activated flowable polymer.
- the application of the method described alsow creates a rnuiti-iaminate structure 100 with the two layers at least partially bonded to one another and a bead structure 15 created by the flow of the energy activated flowable polymer at least partially disposed on the side surface 16 of the first layer 10.
- the bead structure 15 does not require any post processing (with the possible exception of removal of excess polymer which is commonly referred to as flash, that extends from the bead outer surface 17 with a thickness of no more than about 0.2 mm to about 2,0, more preferably less than about 1 ,0 mm, most preferably less than about 0.5mm) and has an untrimmed outer surface 17.
- the multi-layer iaminate structure 100 includes at least four adjoining layers.
- the layers including a first layer 10 including a first top surface portion 12, a first bottom surface portion 14, and a first side surface portion 16 interconnected between the first top and the first bottom portions.
- a second layer 20 including a second top surface portion 22, a second bottom surface portion 24, and a second side surface portion 26 interconnected between the second top and the second bottom portions.
- a third layer 30 including a third top surface portion 32, a third bottom surface portion 34, and a third side surface portion 36 interconnected between the third top and the third bottom portions, wherein the third layer 30 comprises an energy activated flowable polymer ("bonding layer").
- a fourth layer 40 including a fourth top surface portion 42, a fourth bottom surface portion 44, and a fourth side surface portion 46 interconnected between the fourth top and the fourth bottom portions.
- the third layer 30 creates at least a partial bond between the adjoining layers, further contemplated that the third layer 30 at least partially is bonded to a portion of the side surface portion 16 of the first layer 10 creating a bead 15 of the energy activated f iowable polymer about at least a portion of the periphery of the upper layer and the bead 15 has an untrimmed outer surface 17.
- the fourth layer 40 extends past the first through third layers, although this is not necessary,
- the first layer 10 includes a glass plate ("shield layer”).
- the second 20, third 30, or fourth layer 40 includes a photovoltaic ceil assembly ("PV layer”) and/or a back sheet ("back sheet layer”).
- the back sheet may also inciude an integral second energy activated flowable polymer as part of its composition.
- the photovoltaic ceil assembly 70 as seen in Fig. 4, includes at least a cell portion 72 and the ceil portion is at least a distance of about Xmm from an exterior edge of the multi-layer laminate structure 100 or outer surface 17 of the bead 15.
- the multi-iayer laminate structure 100 includes at least six adjoining layers.
- the layers including a first layer 10 (“shield layer”) formed primarily of a glass plate, a second layer 20 (“bonding layer”) formed primarily of an energy activated flowabie poiymer, a third layer 30 (“PV layer”) formed primarily of a photovoltaic cell assembly, a fourth layer 40 (“bonding layer”) formed primarily of an energy activated flowable polymer, a fifth layer 50 (“back sheet layer”) formed primarily of a back sheet as described above, and a sixth layer 60 (“supplemental barrier layer”) formed primarily of a supplemental barrier sheet as described above.
- the bead structure (not shown) is formed by at least one of the energy activated fiowable polymer layers, after forming in the lamination frame 1000. As shown, the sixth layer 60 extends past the first through third layers, although this is not necessary.
- the distance Xmm is about 5.0mm, more preferably about 10,0mm, and most preferably about 15.0mm.
- a unique laminate frame 1000 may be utilized in the manufacture of the multi-layer laminate structure 100.
- the frame 1000 may generally function to provide holding, locating, and dimensional control during the manufacturing of the multi-layer laminate structure 100 and dimensionai consistency of the final part. Applicants have discovered that lack of dimensionai consistency from part to part makes subsequent processing of the laminate structures impractica! due to scrap and breakage particularly when the laminate is processed particularly in tooled equipment such as injection molds or the like.
- Use of the frame in lamination with a bead forming the exterior dimension leads to dimensional consistency that enables subsequent processing (e.g. injection molding) or assembly (e.g. inserting into or onto a secondary component) efficiently and without undue waste.
- the unique laminate frame 1000 also may provide for the net or near net shape of the exterior profile of the multi-layer laminate structure 100.
- the laminate frame 1000 may include a first frame surface, a second frame surface and an externa! side frame surface interconnecting the first and second surfaces thus defining a frame thickness.
- the frame may include an internal side frame surface that projects towards the second frame surface from the first frame surface (at least through a portion of the frame thickness or ail the frame thickness in places) defining a first frame pocket and a first frame pocket side wall profile.
- the frame pocket may be of any of a variety of geometric shapes, for example, the pocket may have 3 (triangular), 4 (rectangular) or more sides or it may consist of a combination of straight and curved portions.
- the frame may also include a plurality of additional frame pockets (e.g. second frame pocket 1102 (e.g.
- third frame pocket generally outside the area of the first frame pocket (although it may be at least partially coextensive) and including side wail profiles and interna! frame surfaces.
- the frame does not have to be 4 sided, but can have up to 6 primary surfaces (e.g. as in a cube or full cavity and core). It is further contemplated that the frame surfaces may or may not be planer so as to accept flat or curved layers as required to produce desired contours.
- the lamination frame 1000 may comprise multiple sets of pockets (where, in the meaning of set of pockets. Figures 5 and 9, individually depict two variations on a set of pockets useful in lamination frames.) !t is anticipated that a frame with multiple sets of pockets may be particularly useful in manufacturing laminations at an increased manufacturing rate in an automated or semi-automated process (i.e., with increased use of robotics).
- the lamination frame 1000 may be made of any number of materials or combination of materials.
- the frame may be constructed to be highly thermally conductive (e.g. aluminum, steel) and preferably has a low thermal capacity, it is also preferably dimensionaily stable with the changes in temperature and (CLTE) and maintains shape (strength and modulus.) it is contemplated that the frame 1000 may be constructed with a non-stick surface (coating or as substrate) so it can be removed from the completed laminate 100 after the energy activated f iowable polymer is cured or cooled to the proper modulus.
- the frame 1000 may be rigid so the multi-layered laminate structure 100 can be forced out without any damage to the frame 1000.
- the frame may be locally more flexible, for example in local area 11 13 of taper 1 112 and/or in the bottom surface of the frame (e.g. as shown in Fig. 7).
- the side wail profile of the any or al! of the pockets may be of any shape, but is preferably tapered inwards by at least about a 1.5° angle, more preferably by at least about a 3.5° angle, and most preferably by at least a 5.0° angle.
- This taper may be present so that finished multi-layered laminate structure 100 can be removed with relative ease (e.g. no die-lock), it is further contemplated that the issue of die lock may be at least partially overcome by the use of insertable frame pieces, flexible frame materials, or any combination thereof, it may also be present to address a previously unrecognized problem is that one cannot be certain that all the layers (e.g.
- the glass layer will be of uniform size or positioned properly inside the lamination frame.
- the tapered edge may insure that the energy activated flowable polymer has a space in which to flow and seal edges or provide for bonding despite being potentially located tightly to the frame.
- the taper is present in at least about the first 10% of the side wail profile (as measured peripherally and vertically), more preferably in at least about the first 20%, and most preferably in at least about the first 50%. It is contemplated that the taper may be present everywhere in the profile or not at all in some pockets.
- the inventive product is an assembly including the laminate frame 1000 as at least partially described herein and the multilayer laminate structure 100 as described above,
- the lamination frame 1000 may also include one or more insertable frame pieces 1020 (disposed separate from or coextensive with any of the pockets). These insertable frame pieces 1020 may function to at least locally alter a profile of the bead 15 and/or may function as an ejection aid (e.g. ejection aid as illustrated in Fig. 9). These pieces are preferably removable from the rest of the lamination frame and may allow for bead profiles that otherwise may create what is commonly known as a "die-lock" condition once the bead has formed.
- the laminate frame may be designed such that it has insertable features or upper and lower sections so as to form geometry on both sides of the laminate and still be removed from the laminate frame after processing.
- Another possible insertable piece may be a close-out frame plate 1030.
- the plate 1030 may help distribute the vacuum load such that the laminate 100 is of a more uniform thickness. This may be especially important where one layer is designed to be of a different size to perform a specific function, for example, in a PV device the PV layer is not the same size as the laminate or where multiple layers overlap and the encapsulant needs to make the adjustment for uniformity of thickness.
- the frame 1000 may also include at least one keeper pocket 1400.
- the keeper pocket 1400 functions to allow the placement of additionai components to the multilayer stack.
- the keeper pocket may also include a keeper cover piece 1410 which is at least partially nested over any additional components that are placed in the keeper pocket.
- the keeper pocket 1400 and keeper cover piece 1410 may aid in controlling the flow of the energy activated flowable polymer in the area of the additional components, in one preferred embodiment, as seen in Fig. 9, the frame 1000 includes two keeper pockets and keeper covers on opposing sides of the frame 1000. These pockets adapted to hold a connector piece 101 (for example as seen in Figs.
- the keeper cover piece 1410 can be a set of individual pieces that cover the keeper pockets 1400 (e.g. as shown in Fig. 9) or may be a single piece that is connected between the pockets 1400 (e.g. as shown in Fig. 10)
- the lamination frame 1000 includes a first frame surface 1010, a second frame surface 1012 and an external side frame surface 1014 interconnecting the first and second surfaces thus defining a frame thickness.
- the frame 1000 may include an internal side frame surface 1014 that projects towards the second frame surface 1012 from the first frame surface 1010 (at least through a portion of the frame thickness or all the frame thickness in places) defining a first frame pocket 1100 and a first frame pocket side wall profile 1110.
- the first frame pocket side wall profile 1110 includes a taper 11 12 of about 1.5° in the first 10% of the profile 1 1 10 as measured vertically, more preferably more than 50% or more.
- the lamination frame 1000 includes an insertable frame piece 1020.
- the insertable frame piece 1020 includes an insert taper 1022 that is opposite to the taper 1112 of the first frame pocket 1 110.
- an optional close-out frame plate 1030 is seen.
- the lamination frame 1000 includes an insertable frame piece 1020, two keeper pockets 1400 and two keeper cover pieces 1410.
- the multi-layer laminate structure 100 may be manufactured with the lamination frame (also as described above) with a method further described below. It is contemplated that the various layers in the multi-layer structure 100 may be loaded into the frame in any number of orders (e.g. pre-stacking some or ail the layers or stacking only in the frame) and orientations (e.g. frame up, frame down, or at any angle in-between), it is contemplated that the frame may be used in a batch process or part of a continuous manufacturing process. For example, in a batch process, a number of frames 1000 are loaded with the layers and then subjected to energy source and/or vacuum as a group. For Example, in a continuous process, the frames 1000 could be on a conveyor system in a series and the loading, unloading and intermediate processing takes place in a continuous manner.
- the frames 1000 could be on a conveyor system in a series and the loading, unloading and intermediate processing takes place in a continuous manner.
- the method may include a number of steps, these steps including: a. providing a lamination frame , wherein the frame includes a first frame surface, a second frame surface and an external side frame surface interconnecting the first and second surfaces defining a frame thickness, further wherein the frame includes an internal side frame surface that projects towards the second frame surface from the first frame surface at least through a portion of the frame thickness defining a first frame pocket and a first frame pocket side wall profile; b. providing a first layer 10 including a first layer top surface portion, first layer bottom surface portion, and a first layer side surface portion interconnected between the top and bottom portions, wherein the first layer 10 has a first layer length and first layer width adapted to fit within the first frame pocket; c.
- a second layer 20 including a second layer top surface portion, second layer bottom surface portion, and a second layer side surface portion interconnected between the top and bottom portions, wherein the second layer 20 includes an energy activated flowable polymer and further wherein the second layer 20 has a second layer length, a second layer width, and a second layer thickness such that it can at least partially fiow into and fill at least a portion of a first gap between the internal side frame surface and the first layer side surface portion; d, providing an energy source; e. introducing the first layer to the first pocket; f. placing the second layer bottom surface portion at least partially in communication with the first iayer top surface portion creating a multi-layer stack; g.
- the energy source to the lamination frame, the multi-layer stack, or both, causing the energy activated flowable polymer to bond to the first iayer 10 and at least partially flow into the first gap between the first layer side surface portion and the internal side frame surface creating a bead with a bead width and a bead depth, the bead depth defined by a depth of the internal side frame surface; h. allowing the energy activated flowable polymer to at least partially solidify, forming the multi-layer laminate structure 100; and i. separating the multi-layer laminate structure 100 from the lamination frame.
- the "energy source” may be provided by any number of methods such as an oven or a system of heating elements.
- energy may be provided to the frame and/or layers via infrared, conductive, convective, microwave, or even chemical means, thus activating the energy activated flowable polymer,
- the frame is placed in a press that is capable of placing the frame/iayers under a vacuum, it is believed that this can aid in directing the flow of the energy activated flowable polymer and the creation of the bead.
- the vacuum may function to remove gasses, both those present from air and those created in the cross-linking of polymers, such as EVA.
- the vacuum function for removal of gasses may be further aided by incorporating venting or fiow channels in the frame through clearances between layers and frame pieces or reliefs or projections in the frame.
- This vacuum may also be used to induce a uniform surface pressure on the laminate through the use of a flexible membrane or bladder. This membrane may also be positively pressurized, so as to increase the compression of the laminate assembly further than that of the vacuum.
- a vacuum press is described in US Patent 5,772,950, hereby incorporated by reference.
- the steps may include any combination of: providing a third layer 30 including a third layer top surface portion, third layer bottom surface portion, and a third layer side surface portion interposed between the top and bottom portions, and placing the third layer 30 in at least partial communication with the second layer top surface portion or with the second layer bottom surface portion; the third layer 30 has a third layer length and third layer width less than that of the first pocket; including causing the energy activated flowable polymer to bond to the third layer 30 and at least partially flow into a third gap between the third layer side surface portion and the interna!
- the third layer 30 has a third layer length and third layer width greater than that of the first pocket; a first pocket length and a first pocket width of the first frame pocket is no greater than about 10 mm, more preferably no greater than about 6 mm and most preferably no greater than about 4 mm larger than the first layer length, the first layer width, or both (although preferably greater than about 0.2 mm, more preferably greater that about 0.4 mm); the second layer length, the second layer width, or both is no greater than about 10 mm, more preferably no greater than about 6 mm and most preferably no greater than about 4 mm larger than that of the first layer 10 (although preferably greater than about 0.2 mm, more preferably greater that about 0.4 mm); providing a second frame pocket including a second frame pocket side wall profile; the second frame pocket includes at least one insertable frame section; the internal side frame surface that projects towards the second frame surface from the first frame surface does so through the entire frame
- the multilayer stack includes at least a glass layer, a photovoltaic cell assembly layer, or a back sheet layer;
- the second layer 20 has a second layer length, a second layer width, and a second layer thickness such that it can flow into and fili the first gap between the interna! side frame surface and the first layer side surface portion Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. Plural structural components can be provided by a single integrated structure.
- any numerical values recited in the above application include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value.
- the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51 , 30 to 32 etc. are expressly enumerated in this specification.
- one unit is considered to be 0.0001 , 0.001 , 0.01 or 0.1 as appropriate.
- ail ranges include both endpoints and all numbers between the endpoints.
- the use of “about” or “approximately” in connection with a range applies to both ends of the range.
- “about 20 to 30” is intended to cover “about 20 to about 30", inclusive of at least the specified endpoints.
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Abstract
Description
Claims
Applications Claiming Priority (2)
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-
2010
- 2010-08-12 ES ES10745095.9T patent/ES2503791T3/en active Active
- 2010-08-12 EP EP10745095.9A patent/EP2464516B1/en not_active Not-in-force
- 2010-08-12 WO PCT/US2010/045284 patent/WO2011019886A1/en active Application Filing
- 2010-08-12 BR BR112012003067A patent/BR112012003067A2/en not_active IP Right Cessation
- 2010-08-12 CN CN201080035550.7A patent/CN102470659B/en not_active Expired - Fee Related
- 2010-08-12 KR KR1020127006405A patent/KR101369824B1/en not_active IP Right Cessation
- 2010-08-12 US US12/855,148 patent/US8163125B2/en not_active Expired - Fee Related
- 2010-08-12 JP JP2012524862A patent/JP5647247B2/en not_active Expired - Fee Related
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2012
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Non-Patent Citations (1)
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See references of WO2011019886A1 * |
Also Published As
Publication number | Publication date |
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US20110036494A1 (en) | 2011-02-17 |
CN102470659B (en) | 2014-10-22 |
US8361602B2 (en) | 2013-01-29 |
BR112012003067A2 (en) | 2019-09-24 |
WO2011019886A1 (en) | 2011-02-17 |
US8163125B2 (en) | 2012-04-24 |
US20120118361A1 (en) | 2012-05-17 |
JP5647247B2 (en) | 2014-12-24 |
JP2013501660A (en) | 2013-01-17 |
CN102470659A (en) | 2012-05-23 |
KR20120055663A (en) | 2012-05-31 |
ES2503791T3 (en) | 2014-10-07 |
EP2464516B1 (en) | 2014-07-02 |
KR101369824B1 (en) | 2014-03-07 |
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